integrating basic lean principles to improve safety ... lean principles and... · integrating basic...

Integrating Basic Lean Principles to Improve Safety Performance

Randy Groll

Black Swamp Safety CouncilAugust 2015

2

Purpose – Response to Survey Results

Answe r Op tio nsRe sp o nse

Pe rce nt

Re sp o nse

Co unt

Sprains/Strains 89.1% 49

Slips and/or Trips 87.3% 48

Cuts 85.5% 47

Falls - on the same level 70.9% 39

Repetitive motion injuries (ie: carpal tunnel) 69.1% 38

Incidents involving lift equipment 60.0% 33

Weather related hazards (slips and falls) 60.0% 33

Caught in or compressed (pinch points) by

equipment58.2% 32

Housekeeping related hazards (clutter induced) 56.4% 31

Incidents involving motorized vehicles 52.7% 29

Struck by object or equipment 52.7% 29

Arc Flash 45.5% 25

Injury from falling/dropped objects 40.0% 22

Falls - from upper levels 36.4% 20

Burns 36.4% 20

Hazardous materials 36.4% 20

Struck against object or equipment 30.9% 17

Combustible materials 29.1% 16

Air quality/respiratory concerns 29.1% 16

Dismemberment (loss of limbs/digits) 23.6% 13

Embedded debris (ie: wood/metal/other 21.8% 12

Drowning 1.8% 1

2

55

0

Other (please specify)

T he fo llo wing sa fe ty co nce rns imp a ct ma ny ind ustry se cto rs . Ple a se

id e ntify the a re a s o f sa fe ty ha za rd s tha t a re re le va nt fo r yo ur

wo rk fo rce . Ple a se che ck a ll tha t a p p ly .

sk ip p e d q ue stio n

a nswe re d q ue stio n

3

0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%

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Safety is a continuous improvement process. With that in mind, which of the following areas of improvementbest

applies to your work environment? (Check all that apply)


Sa fe ty is a co ntinuo us imp ro ve me nt p ro ce ss. W ith tha t

in mind , which o f the fo llo wing a re a s o f imp ro ve me nt

b e st a p p lie s to yo ur wo rk e nv iro nme nt? (Che ck a ll tha t

a p p ly)

Answe r Op tio ns Re sp o nse Pe rce nt Re sp o nse Co unt

A clean and organized work area - items removed from aisles,

trip hazards removed from area80.0% 44

Easy access to Personal Protective Equipment (PPE) and other

safety equipment (fire extinguishers, etc.)

61.8% 34

Auditing and accountability of work areas - checklists,

housekeeping boards, metrics

60.0% 33

A work area with items and equipment identified and tools

placed in a designated space - shadow boards, chemical

storage, etc.

60.0% 33

Identifying and labeling equipment - lock out points, machine

controls, etc.58.2% 32

Using visual controls for standardized work - visual work

instructions, utility identification and flow, indicator lights, etc.

45.5% 25

Other (please specify)2

55

0sk ip p e d q ue stio n


4

Re sp o nse

Pe rce nt

Re sp o nse

Co unt

49.1% 27

25.5% 14

0.0% 0

7.3% 4

5.5% 3

12.7% 7

55

0

40%

skip p e d q ue stio n

Answe r Op tio ns

80%

20%


Wha t p e rce nta g e o f yo ur wo rkfo rce ha s b e e n tra ine d o n Le a n p rinc ip le s?

Fo r Exa mp le 5S syste m (So rt, Se t in Ord e r, Shine , Sta nd a rd ize , a nd

Susta in), s ta nd a rd wo rk, a nd v isua l co ntro ls?

60%

0% (or unfamiliar with these processes)

100%

0% (or unfamiliar with these

processes), 49.1%

20%, 25.5%

40%, 0.0%

60%, 7.3%

80%, 5.5%

100%, 12.7%

What percentage of your workforce has been trained on Lean principles? For Example 5S system (Sort, Set in Order, Shine, Standardize, and Sustain), standard work, and visual controls?

0% (or unfamiliar with theseprocesses)20%

40%

60%

80%

100%


Agenda

Explain why and how an organization can integrate Lean Principles

• 5S• Standard Work• Visual Workplace

Practices• Kaizen – Root Cause

Analysis

to improve workplace safety

5

Lean Safety

Safety

Employee Culture of Safety Awareness to Reduce or eliminate …..

• Incidents

• Accidents

• Injuries

6

Lean

Employee Culture of improving efficiency and eliminating waste by utilizing….

• Clean and organized work processes

• Standardized and Visual work processes

• Measured and audited work processes

7

5S + Safety = 6S

5S - the foundational tool that can support both issues…

• SAFETY

• EFFICIENCY & WASTE

8

It Just Makes Sense!

SORT

SET IN ORDER

SHINESTANDARDIZE

SUSTAIN

SAFETY

5S Process Steps

Sort• Remove unnecessary items from workplace

Set in Order (Straighten)• Organize and label items for easy and efficient use

Shine• Clean work area and equipment

Standardize• Establish documented work processes to support Sort, Set

in Order and Shine

Sustain• “Routine Business Practice” – with audits and measures in

place to monitor success

9

5S is more than housekeeping!

6S - Sort

WHY?

• Pinch Points

• Trip, Slip or Fall

• Incidents

• Evacuation

10

Incident

Slip Evacuation

Pinch Points

6S - Sort

HOW?

Remove unnecessary items

“Red Tag” items

11

Chemicals

Tools Materials

WHY?

• Sprains and Strains

12

6S - Set in Order (Straighten)

Lifting

85% Rule

Muri

WHY?

• Injury

13


WHY?

• Burns

• Explosion

14


Explosions

Fires

Chemicals


HOW?

Organize and Label for efficient use

15

Workstation

BordersUtilities


HOW?


16

Tools and Equipment

SuppliesEase of use – Lifting


HOW?


17

Fire Extinguishers

Eye Wash Stations

PPE


HOW?


18

Locks

Lock Out Machine Guarding


HOW?


19

Chemical Labeling

Chemical Storage

Supply Storage

6S - Shine

WHY?

• Avoid slips, trips, falls

• Accidents

20

Leaks

Off Standard ConditionsOil

6S - Shine

HOW?

Clean Work Areas

21

Drains

Floors Lighting

6S - Shine

HOW?

Clean Equipment

22

Pumps

Mobil Equipment

Equipment

6S - Standardize

Why?

• Standardized Processes reduces risk of injury

• Understand process and expectations

• Eliminates confusion

23

Standard Work is the BEST METHOD of Performing Task

6S - Standardize

HOW?

Consistent Methods(Standard Work and Visual Management)

24

Evacuation Routes

Workstation Layout Work Practices

6S - Standardize

HOW?

Consistent Methods(Standard Work and Visual Management)

25 Safety Rules

Materials

OSHA Guidelines

6S - Sustain

Why?

• Maintain Results

• Identify Opportunities

26

Audit

Track Results

Prioritize Issues

6S - Sustain

HOW?

Promote Awareness

• Monitor

• Maintain

27

Policies Hazard Awareness Training Plan

Procedures

Kaizen + Safety

Why?

• Resolve issues with disciplined Root Cause Corrective Action & Analysis (RCCA) – A3

28

Kaizen RCCA Process

Summary

What do you currently do?

What could you do?

29

30

Contact Information

Randy Groll D&R Continuous Improvement Systems

Phone: 419-956-1173

E-Mail: [email protected]

Website: lean6quallity.com

Mary Agostini A&W Continuous Improvement Systems

Phone: 419-261-1490

E-Mail: [email protected]

mailto:[email protected]

mailto:[email protected]

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